Actually, in the Earth's crust, aluminum is more common than carbon by a factor of about 200. Only oxygen and silicon are more common. Source. [wikipedia.org]
Talk to a chemEng about the nightmare of aluminium refining. Its not just that the hall process takes a lot of electricity mostly from burning coal, but it only works with alumina. You gotta run raw bauxite thru the Bayer process which is a whole nother PITA to pre-refine it before it hits the electrochemical cells as alumina. Most bauxite comes from Australia and Brazil, and there's only a "couple centuries worth" and then thats it for bauxite, so aside from recycling it'll be back to the old days before the Hall process where Aluminum was basically a precious metal. Aluminum really is a huge unholy pain in the ass to refine into usable metal.
Its kinda like nitrogen. Plants REALLY need nitrogen. But we all live in a great seemingly infinite pool of nitrogen gas, you say so whats the problem. Yeah but biochemically its a PITA to use N2 straight outta the air, so it (mostly) doesn't happen. Leading to all kinds of chemEng foolishness with ammonia and nitrogen fixing bacteria on legumes etc etc.
Having some atoms laying around doesn't mean they're convenient to use, or practical to use, or possible to use.
Source: http://rss.slashdot.org/~r/Slashdot/slashdotScience/~3/nPHtonbIbRo/story01.htm
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